Machine for assembling and heating dynamo electric machine elements



Feb. 2, 1932. v. G. APPLE 1,843,592

MACHINE FOR ASSEMBLING AND HEATING DYNAMO ELECTRIC MACHINE ELEMENTSOriginal Filed June 14, 1928 Patented Feb. 2, 1932 narr res VINCENT G.APPLE,

or DAYTON, onro MACHINE FOR ASSEMBLING AND HEATING DYNAMOELEOTRIC'MACHINE ELEMENTS Original application filed .Tune 14, 1928,Serial No. 285,363. Divided. and this application filed March 7,

1930. Serial This invention is a division of my copending applicationSerial Number 285,363, filed June 14th, 1928, and relates to a machinefor assembling and cementing together insulation coated core laminae andsimilarly coated conductor bars, compacting the laminae on the bars andheating them while so compacted to bind the laminae together and tothebars.

The object of the invention is to provide a machine wherein a completeset of the conductor bars, previously heavily coated with a cementitiousinsulation are held in cylindrical formation within a mold, while theperforated laminae intended to compose the core also previously coatedwith the insulation are rapidly threaded over the bars, compressed inthe mold, held there, heated to harden and unify the mass, then forcedby pressure from the mold.

I attain this ob 'ect by the mechanismhereinafter described, referencebeing had to the drawings, wherein Fig. 1 is a conventional laminatedconductor bar of the type herein employed to illustrate my invention.

Fig. 2 is the same conductor bar provided with insulation.

Figs. 3 and 4 are sections on the lines 3-3 and 4:4 of Figs. 1 and 2.

Fig. 5 shows a threading cap in perspective.

Fig. 6 shows a pair of coated conductors placed edge to edge in therelation which they occupy when assembled in the core, and a capcovering one end of the pair to facilitate threading the apertures ofthe laminae over the bars.

Fig. 7 shows a segmental laminae of a type readily assembled and madeinto a core by my machine.

Fig. 8 is a vertical. axial section through the machine itself.

Similar numerals refer to similar parts throughout the several views.

To illustrate the operation of my machine I show it as employed in themaking of an alternating current stator of relatively large proportionssuch as maybe used as part of a turbo generator or synchronous motor. To

No. 434,00o;

consist of a mixture of synthetic resin, iron. free silica sand, limeand a flux such as feldspar, fluorspar or sodaash and maybe applied ofconsiderable greater thickness and length than required, in its finishedform. The conductors so covered may then be placed in a die to whichjust enough pressure.

and heat is applied to bring about the reaction of the synthetic resins,and when removed from the die the covering is sufliciently hard, smooth,and accurate for further steps in the process. y

,A conductor so treated and removed from the die is shown at 12, Figs. 2and 4;, where 13 is the covering of insulation surrounding the laminae10, 10, etc. "of the conductor and 14 and 14: the ends which are leftuncovered to facilitate subsequent connection to form a winding.

In conformity with present practice I use as a core for my stator aplurality of segmental sheet stampings as shown at 15, Fig. 7 a

series of such segments composing a layer and;

a suflicient number of layers the core. Perforations 16 are of a sizeand form which may contain two covered conductors Fig. 2 placed edge toedge. Perforations shown are known as of the closedtvpe. The stampingsmay be coated or not as desired but when coated the insulating compoundused may preferably be of the same nature as that used onthe con- 9ductors. v

A hydraulic cylinder 18 having a wide flange 19 and containing a hollowram 20 is supported on concrete base 21. Extending vertically fromflange 19 are columns 22'and supported on the upper end thereof by wideflange 23 is a hydraulic cylinder 24 containing ram 25. Intermediate offlanges 19and 23 and supported by columns 22 is another flange 26 havinga downwardly extending ram 27 and an upwardly extending cylinder 28, theram 27 being fitted to a bore in ram 20 and the cylinder 28 being ofoutside diameter equal to the bore of the stator being assembled, and ofinside diameter suitable to receive another ram 29. Concentric withcylinder 28 and mounted on flange 26 is a cylindrical member 30 havingan inside diameter equal to the outside diameter of the stator to beassembled.

In the space between cylinder 28 and member 30 is a cylindrical ring 31the outside and inside diameters of which are equal to those of thestator to be assembled. The upper side of ring 31 contains a series ofpockets 32 equal in number to the apertures 16 of the core to beassembled, a pocket 32 being of such size that conductors paired edge toedge as in Fig. 6 may have the ends 14, 14 entered therein and a portionof the insulated part 13. 13 as well, the depth of the pocketsbeing suchthat the portion of the conductors which are to extend beyond the corewill be entirely contained in the pockets. Fastened to and extendingdownwardly from ring 31 through openings in flange 26, rods 33 connectto flange 34 of ram 20 so that when valve admits fluid underv pressurethrough pipe 36, ring 31 is moved upwardly by ram 20 through rods 33 andwhen valve 37 admits fluid under pressure through pipe 38. ring 31 isreturned downwardly by ram 20 through rods 33.

At the lower end of ram 25 is a sleeve 39 flanged inwardly at the bottomend as at 40 the flange having through-perforations of a number and sizecorresponding to the apertures 16 of the core being assembled. Cables 41fastened to lugs 42 and passing over sheaves 43 supported by lugs 44 ofcylinder 24 connect to a motor hoist not shown by means of which flange40 maybe rapidly raised or lowered when no hydraulic effect is beingapplied to ram 25. A high frequency coil 45 made of rectangular coppertubing surrounds part 30 for the purpose of generating heatin the metalmasses within by eddy current effect so that the mold and productbecomes in effect a high frequency induction furnace. Insulation 46serves to confine the heat and prevent short circuits between the coils.

To carry forward my method by means of the above described press I firstraise sleeve 39 well above the top of member 30 then I stand verticallyin each pocket of ring 31 a pair of conductors assembled edge to edge asshown in Fig. 6. each pair comprisingone long inner layer conductor anda relatively shorter outer layer conducton and placing on the upper endof each pair a spear-shaped cap 47. The cap 47 is separately and moreclearly shown in Fi 5. I now place suificient stampings 15 for one layerof the core over caps 47, then sufficient stampings for another lay ,royer caps 47 in such a way that the joints between successive stampingsof one layer will be intermediate the joints of the other layer After anumber ot layers have been so placed over the caps 47 the sleeve 39 maybe rapic ly let down by the motor hoist until the perforated flange 40drives the stainpings downward over the con ductors 12 against ring 31when the sleeve may be returned to its upper limit of travel and morestampings threaded on. This process is repeated until sufficientstampings have been placed to complete the core. The sleeve 39 is thenbrought down against the stampings and valve 48 is opened allowingliquid under pressure to flow through pipe 49 into hydraulic cylinder 24and acting through ram 25 against sleeve 39 applying great pres sure tothe assembled structure. High trequency current is then turned into coil45 to heat the structure under pressure and it the stampings have beencoated the heat thus gen erated fluxes the insulating compound betweenthem and the maintained pressure on sleeve 39 evenly distributes theinsulating material between them forcing the excess material into theminute spaces between the conductors and core apertures so that theconductors will be so firmly bound in the core to effectively preventany subsequent shitting of their relative positions. 7

Since any mixture applied to the'stampings should be of similar materialto that previousy applied to the conductors the gradually rising heatfirst brings about the reaction of the synthetic resins bringing themixture on the stampings to a state equal to that on the conductors butas a considerablyhigher'heat is obtainable with. the high frequency coiland as the mixture as previously stated may contain also iron treesilica sand, lime feldspar, fluorspar, soda ash or other flux the heatis carried higher and the synthetic resins are converted. to carbonwhich as the yitritying state of the mixture is reached combines withthe silica forming silica-carbide as the insulating material. The limecontent may in such proportion as will by its effect of causingexpansion of the mixture as it reaches its final state, assist inbinding the conductors tightly in the core apertures. and the flux insuch. proportion as is needed to control. the vitritying temperature.

While I have herein suggested for insulating; one mixture suitable to myprecess any other mixture may be used which may be brought to a vitreoussta e by degree ct he at lower than that which would permanently injurethe copper in the conductors.

After the insulating compound has been brought to the desired state thecurrent in ins coil 45 is shut off and valve 48 is closed, the liquid incylinder 24 by-passed and valve 50 opened so that liquid admittedthrough pipe 51 acts hydraulically against ram 29 raising same until itcarries with it sleeve 39 thus stripping flanged end 40 from the ends ofthe conductors. After flange ID has been stripped from the conductorsram 29 is returned and the motor hoist is employed to return sleeve 39to its upper position. Valve 35 is next opened so that ram 20 throughrods 33 raises ring 31 to strip the core from the die. In order toloosen the ends of the conductors from the pockets 32 of ring 31 thecore is first raised a short distance only by ram 20. By then openingvalve 37 ram 20 is returned thus stripping pockets 32 from the ends ofthe conductors. By repeating this operation several times the ends willbe loose enough in the pockets so that when the core is raised clear ofthe die it may be held by other means and the ring 31 returned to itslower position.

After the assembled core and conductor structure is removed from themachine the bare ends 14 of the conductors may be joined in pairs by endconnectors of any of the conventional designs usually employed for thispurpose but which, forming no part of the present invention, are notherein shown, and while I have shown my machine as employed in themaking of a stator unit, it is obvious that dynamo electric machinerotor units may be produced with equal facility, and while I have shownconductors of laminar structure, solid conductors may be used ifdesirable, and while the laminae employed have completely closedapertures, semiclosed or open apertures may be employed.

Having described my invention, I claim 1. As part of a machine forentering insulation covered conductor bars placed edge to edge in pairs,with bare ends, into winding apertures of dynamo electric machine corelaminae, an outwardly tapering cap having inside dimensions adapted tofit over the bare ends and outside dimensions equal to the insulationcovered portion of the pair.

2. As part of a machine for entering insulation covered conductor barsplaced edge to edge in pairs, the one bar of a pair being longer thanthe other bar and the ends of the bars being bare of insulation, intowinding apertures of dynamo electric machine core laminae, an outwardlytapering cap having inside dimensions adapted to fit over the bare endsof the bar, outside dimensions equal to the insulation covered portionof the pair, and an offset inner end to compensate for the difference inlength between the two bars.

3. In a machine for assembling insulation covered conductors and corelaminm of a dynamic electric machine element, the combination of acylinder having outside diameter corresponding to the inside diameter ofthe core, a ring recessed in its side to receive such part of the endsof the bars as is to extend beyond the end of the core, means to pressthe laminae over the conductors and around the cylinder, and heatingmeans surrounding said core.

4. In a machine for assembling insulation covered conductors and corelaminae of a dynamo electric machine element, the combination of amember having an opening corresponding to the outside dimensions of thefinished core, a ring recess-ed in its side to receive such part of theends of the bars as is intended toextend beyond the end of the core,means to press the laminae over the conductors and into the said openingand heating means surrounding the said opening.

5. In a machine for assembling core laminae over insulation coatedconductors of a dynamo electric machine element, the combination of acylinder having an outside diameter corresponding to the inside diameterof the core, a ring surrounding said cylinder having a plurality ofpockets corresponding to the part of the bars which is to extend beyondthe end of the core, means to press the laminae over the conductors andaround the said cylinder and means to move said ring axially over saidcylinder.

6. In a machine for assembling core laminm over insulation coveredconductors of a dynamo electric machine element, the combination of acylinder having an outside diameter corresponding to the inside diameterof the core, a member surrounding said cylinder having an insidediameter conforming to the outside of said core,a narrow ring adapted tofill the space between said cylinder and said member at one end, saidnarrow ring having a plurality of pockets corresponding to the part ofthe bars which is to extend beyond the end of the core, a wide ringadapted to fill the space between said. cylinder and said member at theother end, said wide ring being recessed to receive the bars for thegreater part of their length, means to move the wide ring axially in onedirection to compact the several laminae of the core, and means to movethe narrow ring axially in the other direction to eject the core frombetween the said cylinder and the said member, after it is compactedtherebetween.

7. In a machine for assembling core laminae over insulation coveredconductors 'of a dynamo electric machine element, the combination of acylinder corresponding in outside diameter to the bore of the core, acylindrical member corresponding in outside diameter to the outsidediameter of the element, a ring and a sleeve'each having inner and outerdiameters corresponding to the outer and inner diameters of the cylinderand cylindrical member respectively, and means to move said ring andsaid sleeve axially betWeen said cylinder and said cylindrical member.

8. In a machine for assembling the laminm of a core over insulationcovered conductors of a dynamo electric machine element, the combinationof means to hold the conductors at one end and in the arrangementrequired in the finished element means to press the laminae over theother end of the conductors While so held, means to align the laminae inconcentric relation one to the other as they are assembled, and means tostrip the completed structure from the aligning means.

In testimony whereof I aflix my signature.

VINCENT G. APPLE.

